fanuc GFZ-62075E-03 Maintenance Manua

GE Fanuc Automation

Computer Numerical Control Products

Series 15 / 150 – Model B

Maintenance Manual

GFZ-62075E/03

February 1995

GFL-001

Warnings, Cautions, and Notes as Used in this Publication

Warning

Warning notices are used in this publication to emphasize that hazardous voltages, currents, temperatures, or other conditions that could cause personal injury exist in this equipment or may be associated with its use.

In situations where inattention could cause either personal injury or damage to equipment, a Warning notice is used.

Caution

Caution notices are used where equipment might be damaged if care is not taken.

Note

Notes merely call attention to information that is especially significant to understanding and operating the equipment.

This document is based on information available at the time of its publication. While efforts have been made to be accurate, the information contained herein does not purport to cover all details or variations in hardware or software, nor to provide for every possible contingency in connection with installation, operation, or maintenance. Features may be described herein which are not present in all hardware and software systems. GE Fanuc Automation assumes no obligation of notice to holders of this document with respect to changes subsequently made.

GE Fanuc Automation makes no representation or warranty, expressed, implied, or statutory with respect to, and assumes no responsibility for the accuracy, completeness, sufficiency, or usefulness of the information contained herein. No warranties of merchantability or fitness for purpose shall apply.

©Copyright 1995 GE Fanuc Automation North America, Inc.

All Rights Reserved.

B±62075E/03	Table of contents

1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .			1
1.1	Configuration of the CNC Control Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		3
	1.1.1	Configuration of the CNC control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3
	1.1.2	Configuration of the printed circuit boards in the CNC control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	5
	1.1.3	Configuration of the CRT/MDI unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	5
1.2	Block Diagram for the CNC Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		6
1.3	List of the Printed Circuit Boards and Units of Series 15±B . . . . . . . . . . . . . . . . . . . . . . . . .		9

2. MAINTENANCE EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .			16
2.1	Maintenance Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		16
2.2	Main Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		16
3. TROUBLESHOOTING AND ACTION TO BE TAKEN . . . . . . . . . . . . . . . . . . . . . . .			17
3.1	Procedures for Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		17
3.2	Problems and Corrective Measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		17
	3.2.1	System alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	17
	3.2.2	Action to be taken when an error code is displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	18
	3.2.3	Lighting of alarm LEDs on PCBs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	22
	3.2.4	The machine cannot be operated in the jog mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	23
	3.2.5	The machine cannot be operated by the manual pulse generator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	24
	3.2.6	The spindle cannot be operated in the synchronous feed mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	24
	3.2.7	The machine cannot be operated in the automatic mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	25
	3.2.8	The input/output unit of the reader/punch interface do not operate correctly. . . . . . . . . . . . . . . . . . . . . . . .	26
	3.2.9	The machine does not return to the correct reference position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	27
3.3	Displaying Conditions Using the Self±diagnosis Function . . . . . . . . . . . . . . . . . . . . . . . . . .		30
	3.3.1	Diagnosis function for the interface with machine tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	30
	3.3.2	Function to display the CNC internal status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	31
3.4	Displaying System Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		39
4. CONFIRMING POWER SOURCE VOLTAGE AND
POWER CONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .			44
4.1	Confirming Power Source Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		44
	4.1.1	Power supply in the control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	44
	4.1.2	Servo amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	46
	4.1.3	Checking the ground connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	46
4.2	Confirmation of Power Supply Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		47
	4.2.1	Tap change of control power transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	47
	4.2.2	Connection of AC servo power transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	47
4.3	Confirming CNC Control Unit Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		48
	4.3.1	Series 15±MB total connection diagram (In case of serial spindle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	48
	4.3.2 Connection of FANUC I/O Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		51
	4.3.3	Optical fiber cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	54
	4.3.4 Connection of I/O Unit±MODEL A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		58

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4.3.5	Connection with Connection unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	62
4.3.6	Connection of operator's panel connection unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	63
4.3.7	CRT display interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	66
4.3.8	LCD PDP display interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	67
4.3.9	Keyboard interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	67
4.3.10Manual pulse generator interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		68
4.3.11Remote buffer interface (RS±232±C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		68
4.3.12Remote buffer interface (RS±422) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		69
4.4 Confirmation of Connection between CNC Control Unit and Servo . . . . . . . . . . . . . . . . . . .		70
4.5 Confirming the Connection between the CNC Control Unit and Spindle Motor . . . . . . . . . .		74
4.6 Confirming the Connection between the NC Control Unit and I/O devices . . . . . . . . . . . . . .		77
4.6.1	RS±232±C serial port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	77
4.6.2	PPR connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	78
4.6.3	Portable tape reader connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	79
4.6.4	FANUC Cassette connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	80
4.6.5	Connection of tape reader without reels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	81
4.6.6	Connection of tape reader with reels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	82

5. STARTUP AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .			83
5.1	Startup and Adjustment Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		83
5.2	Adjusting a Flat Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		87
6. DISPLAYING AND SPECIFYING PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . .			88
6.1	Displaying Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		88
	6.1.1	Displaying parameters other than those related to pitch error compensation . . . . . . . . . . . . . . . . . . . . . . . .	88
	6.1.2	Displaying parameters related to pitch error compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	88
6.2	Specifying Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		89
	6.2.1	Formats of parameter tapes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	89
	6.2.2	Specifying parameters through the reader/punch interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	91
	6.2.3	Specifying parameters through the MDI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	91
6.3	Outputting Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		92
	6.3.1	Outputting all parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	92
	6.3.2	Outputting the parameters excluding those related to pitch error compensation . . . . . . . . . . . . . . . . . . . . .	92
	6.3.3	Outputting parameters for pitch error compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	92
6.4	Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		93
6.5	Setting and Displaying PMC Data (using the PCPRM soft key) . . . . . . . . . . . . . . . . . . . . . .		103
	6.5.1	Setting and displaying timer data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	103
	6.5.2	Setting and displaying counter data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	104
	6.5.3	Setting and displaying keep relay data and data for controlling the retained memory . . . . . . . . . . . . . . . . .	104
	6.5.4	Setting and displaying data in the data table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	105
	6.5.5	Inputting and outputting PMC data (when the reader/punch interface is used) . . . . . . . . . . . . . . . . . . . . . .	107
6.6	Input/Output of CNC Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		111

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6.6.1	Setting the parameters necessary for input/output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	111
6.6.2	Outputting CNC parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	115
6.6.3	Outputting part programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	115
6.6.4	Outputting offset data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	115
6.6.5	Inputting CNC parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	115
6.6.6	Inputting part programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	115
6.6.7	Inputting offset data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	116

7. CONFIGURATION OF THE PRINTED CIRCUIT BOARDS
IN THE CONTROL UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .			117
7.1	Power Unit Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		117
7.2	Configuration of the CPU Board (MAIN±B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		119
7.3	Configuration of the Main CPU Board (MAIN±A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		123
7.4	Configuration of the Upgraded Main CPU Board (MAIN±C) . . . . . . . . . . . . . . . . . . . . . . . .		127
7.5	Configuration of the High±Speed Multiaxis Main CPU Board (MAX MAIN±A) . . . . . . . .		130
7.6	Configuration of the PMC±NA Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		134
7.7	Configuration of the PMC±NA Board with or without the Conversational Function . . . . . .		137
7.8	Configuration of the PMC±NB Board with or without the Conversational Function . . . . . .		140
7.9	Configuration of the Axis CPU Board (ACPU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		143
7.10	Configuration of the Multiaxis Buffer Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		146
7.11	Configuration of the RISC Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		148
7.12	Configuration of the Sub. CPU board (SUB±A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		150
7.13	Configuration of the Standard Multiaxis Sub±CPU Board (MAX SUB±B) . . . . . . . . . . . . .		153
7.14	Configuration of the Upgraded Sub±CPU Board (SUB±C) . . . . . . . . . . . . . . . . . . . . . . . . . .		156
7.15	Configuration of additional axis (ADAX) board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		159
7.16	Configuration of the option 1 board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		161
8. HOW TO REPLACE FUSES, PRINTED CIRCUIT BOARDS,
AND OTHER UNITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .			165
8.1	How to Replace the Fuses in the Power Supply Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		165
8.2	How to Replace the Power Supply Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		166
8.3	How to Replace the Printed Circuit Boards in the Control Unit . . . . . . . . . . . . . . . . . . . . . . .		167
8.4	How to Replace the Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		168
8.5	How to Replace the Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		169
	8.5.1	Procedure for replacing the dry cell for the control unit (memory back±up) . . . . . . . . . . . . . . . . . . . . . . . .	169
	8.5.2	Procedure for replacing the dry cell for the absolute pulse coder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	170
8.6	How to Replace the Fan Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		171
8.7	How to Replace the Card Cage in the Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		172
8.8	How to Replace the MDI Keyboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		173
8.9	How to Replace the CRT Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		174

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APPENDIX

1. SYSTEM ALARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .			177
1.1	System Alarms When the CNC System Is Turned On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		177
1.2	System Alarms While the CNC System Is Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		179
	1.2.1	System alarm screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	179
	1.2.2	Software series and edition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	179
	1.2.3 System alarms (SYSTEM ALARM FACTOR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		180
1.3	Program Counter (PROG COUNT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		182
1.4	CPU Status (CPU STATUS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		182
1.5	User Number for the Active Task (ACT TASK) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		182
1.6	Address at which an Error Occurred (ERROR ADRS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		182
1.7	Master CPU of the Bus (BUS MASTER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		182
1.8	Hardware Status (HARD INFORMATION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		183
1.9	Software Status (SOFT INFORMATION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		183
2. DISPLAYING THE SYSTEM LOG SCREEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .			184
3. SIGNAL INTERFACE LIST BETWEEN CNC AND PMC . . . . . . . . . . . . . . . . . . . .			185

iv

B±62075E/03	1. GENERAL

1. GENERAL

This manual describes preventive maintenance, quick troubleshooting procedures, check points, adjustments, and parameter details. It also covers various additional technical information (Appendixes).

Refer to the OPERATOR'S MANUAL and CONNECTING MANUAL, as required.

The CNC is an integral part of the CNC machine tool. A dust±proof enclosed structure, a cooling method, and wiring between units are designed and manufacured by each machine tool builder. Refer to the machine tool builder manual that addresses these issues.

Refer to the following materials for the details of the information listed below:

Parameters for the digital servo unit:

FANUC AC SERVO AMPLIFIER MAINTENANCE MANUAL (B±65005E)

FANUC AC SERVO MOTOR αSeries PARAMETER MANUAL (B±65150E)

DI/DO interface between the CNC and PMC:FANUC Series 15±MODEL B CONNECTION MANUAL (B±62073E)

Related manuals of FANUC Series 15±MODEL B are as follows:

FANUC Series 15±MODEL B DESCRIPTION (B±62072E)

FANUC Series 15/150±MODEL B CONNECTION MANUAL (B±62073E)

FANUC Series 15±MODEL B CONNECTION MANUAL (BMI interface) (B±62073E±1)

FANUC Series 15±MODEL B For Lathe OPERATOR'S MANUAL (PROGRAMMING) (B±62554E/01)

FANUC Series 15±MODEL B For Lathe OPERATOR'S MANUAL (OPERATION) (B±62554E±1/01)

FANUC Series 15±MODEL B For Machining Center OPERATOR'S MANUAL (PROGRAMMING) (B±62564E/01)

FANUC Series 15±MODEL B For Machining Center OPERATOR'S MANUAL (OPERATION) (B±62564E±1/01)

FANUC Series 15±MODEL B PARAMETER MANUAL (B±62560/01)

*FANUC Series 15/150±MODEL B MAINTENANCE MANUAL (B±62075E)

FANUC PMC±MODEL N/NA PROGRAMMING MANUAL (Ladder Language) (B±61013E) FANUC PMC±MODEL N/NA PROGRAMMING MANUAL (PASCAL Language) (B±61013E±1) FANUC PMC±MODEL N/NA PROGRAMMING MANUAL (C Language) (B±61013E±2)

CONVERSATIONAL AUTOMATIC PROGRAMMING FUNCTION FOR LATHE

(Series 16, Series 15±MODEL B) OPERATOR'S MANUAL (B±61804E±2)

CONVERSATIONAL AUTOMATIC PROGRAMMING FUNCTION FOR MACHINING CENTER (Series 15±MF, Series 15±MFB) PROGRAMMING MANUAL (B±61263E)

CONVERSATIONAL AUTOMATIC PROGRAMMING FUNCTION FOR MACHINING CENTER (Series 15±MF, Series 15±MFB) OPERATOR'S MANUAL (B±61264E)

*This manual.

± 1 ±

1. GENERAL					B±62075E/03
This manual describes the following products:
	Product name		Abbreviations
	FANUC Series 15 ± TB	15	± TB
	FANUC Series 150 ± TB
	FANUC Series 15 ± TFB	15	± TFB
	FANUC Series 15 ± TTB	15	± TTB
				Series 15 ± B
	FANUC Series 150 ± TTB
	FANUC Series 15 ± TTFB	15	± TTFB
	FANUC Series 15 ± MB	15	± MB
	FANUC Series 150 ± MB
	FANUC Series 15 ± MFB	15	± MFB

NOTE For maintenance of FANUC MMC±IV, see ªFANUC MMC±IV Connection and Maintenance Manual (B±62493E)º.

Explanation of terms frequently used in CNC are:

Least input increment

The minimum unit for program input of the move command

Least command increment

The minimum unit of a command to be given from CNC to the machine tool

Detection unit

The minimum unit of detectable axis move distance

Command multiplier (CMR)

A constant to enable the weight of CNC command pulses to match the weight of pulses from the detector

Detection multiplier (DMR)

A constant to enable the weight of CNC command pulses to match the weight of pulses from the detector

NOTE The relations among the least input increment, detection unit, CMR, and DMR are as specified below.

Least input increment= CMR × detection unit

Detection unit= Move amount per revolution of motor/(DMR ×number of pulses of detector per revolution of motor)

The flexible feed gear function in the digital servo unit defines constant DMR using two parameters n and m (DMR = n/m).

CRT/MDI panel

CRT and Manual Data Input

This operator's panel is used to input command to CNC or display CNC conditions using key switches.

Parameter

A value set in the CNC which enables the CNC to fully utilize the machine tools functional characteristics.

± 2 ±

B±62075E/03	1. GENERAL

1.1 Configuration of the CNC Control Equipment

The CNC control equipment consists of the following: the CNC control unit performing arithmetic processing for numerical control, the CRT/MDI unit displaying set data, the servo motors which actually operate the machine tool, and the servo amplifier. In this section, the structure and internal configuration of the CNC control unit and CRT/MDI unit will be outlined.

1.1.1 Configuration of the CNC control unit

The CNC control unit consists of the control unit rack, the power unit and printed circuit boards installed in the rack.

On top of the rack is a cooling fan motor. At the rear there is a back plane in which the printed circuit boards are pluged. As shown in the figure below, the upper cover of the control rack opens providing access to the fan motor for possible replacement.

The power unit is installed in the slot closest to the right edge of the rack. The PMC board is inserted into the second slot (slot 1) from the right rack edge. The main CPU board is inserted into the third slot (slot 2) from the right rack edge.

When sub CPU board (or editional axis board) is inserted, it is inserted into the fourth slot (slot 3) from the right rack edge. The remaining other slots are used for option boards. The sequence order of the option boards in the option slots makes no difference in the CNC operation. However, in order to avoid confusion, option boards are inserted according to kinds of the boards.

a

a

a d

a U a d

U a d a d

a

a a

d

a d

Fig. 1.1.1 (a) Control Unit Structure

± 3 ±

1. GENERAL	B±62075E/03

Various racks for a control unit, power units, and printed circuit boards shown in the figure below can be used to configure a control units. Combination of these components depends on a machine tool for which the control unit is used.

Fig. 1.1.1 (b) shows the configuration of the control unit of the Series 15±B.

Control unit rack

Three slots Four slots

Six slots

Eight slots

Power unit

Unit which supplies DC voltages to the control

unit printed circuit boards. The power unit

selected depends on the output power

requirements.

PMC board

Board equipped with the PMC control

or

functions.

PMC/CAP board

The board can be PMC/CAP board including

conversational automatic programming

function.

Main CPU board

Board equipped with servo control up to 4 axes

is available.

Sub board

Board equipped with the additional axis

fuction.

The board may be Sub CPU board that mounts

a Sub CPU, or additional axis board (ADAX)

that mounts no Sub CPU.

Option 3 board

Board equipped with graphic display function

and communication function.

Option Boards

Fig. 1.1.1 (b) Configuration of the Control Unit (Series 15±B)

± 4 ±

B±62075E/03	1. GENERAL

1.1.2 Configuration of the printed circuit boards in the CNC control unit

As shown in Fig. 1.1.2, a printed circuit board consists of a printed circuit board and a number of modules installed perpendicularly to the board.

At the front of a printed circuit board, the interface connectors and LED display are installed and a plastic front panel is attached. There is also a connector attached at the rear edge of the printed circuit board for connecting to the F±BUS back plane.

The modules are small printed circuit boards with surface mount devices mounted on both sides. One edge of each module board has connector electrodes. Module boards are attached by inserting them in the module connectors on the printed circuit board, simplifying the replacement of the module boards. There are a number of modules types available and the circuit function for each is different. Therefore, the connector location for installing each module on the printed circuit board is fixed. If a module is not installed in the correct connector, the system may fail to operate correctly and the circuitry of the control unit or the module itself may be damaged. However, some modules (ROM, SRAM, etc.) are interchangeable with respect to the signal assignment, enabling the insertion of the module to the connector of the interchangeable module.

	ÎÎÎÎ
	ÎÎÎ	LED dispaly
	ÎÎÎ
Module	ÎÎÎ
	ÎÎ	Interface connector
onnector
electrodes	Î
	Î
	Î
ack plane connector	Î

Printed circuit board in the control unit

Front panel

Fig. 1.1.2 Configuration of the Printed Circuit Boards in the CNC Control Unit

1.1.3 Configuration of the CRT/MDI unit

The CRT/MDI unit consists of the parts shown in Fig. 1.1.3 The unit is constructed of a CRT display and plastic panel screwed to a metal panel.

RT display

ON button

OFF button

ООООО ООО

ОООООÎÎÎ

ООООО ООО

ÎÎÎ

MDI keyboard

Metal panel

Keyboard for soft keys

Panel

Fig. 1.1.3 CRT/MDI Unit Configuration

± 5 ±

1. GENERAL	B±62075E/03

1.2 Block Diagram for the CNC Control Unit

Series 15±B block diagram for the CNC control unit is described in fig. 1.2 (a) to (c).

Power unit

Switching

ON/OFF power

regulator

control

PMC/CAP board

CPU

BOOT ROM

PMC engine

ROM

Memory card I/F

RAM

With conversational

FLASH ROM

function only

CPU

ROM

RAM

Main CPU board

RAM

FLASH ROM

SRAM

CPU

SERVO control

CRT control

MDI interface

Serial port

MPG interface

High-speed DI

Spindle control

Sub. CPU or additional board

CPU*

CPU

RAM*

SERVO control

Serial port

* Sub. CPU board

High-DI

only

A/D, D/A

Spindle control

Option 1 board

CPU

ROM

CRT control

RAM

Graphic control

CPU

ROM

Communications

RAM

DMA control

200 VAC, single phase

I/O unit

Memory card

Axes 1 to 4

Servo amp.

Pulse coder	Servo motor
CRT/MDI

RS232C × 2

MPG

High-speed SKIP

Spindle amp.

	Spindle motor
Axes 5 to 8
Servo amp.
Pulse coder	Servo motor

RS232C × 1, RS422 × 1

High-speed SKIP

ANALOG I/O

Spindle amp.

Spindle motor

to CRT/MDI

Host computer

FAN

NOTE Only the main boards are listed in this diagram

FANUC BUS

Fig. 1.2 (a) Block Diagram for Series 15±B Standard System

± 6 ±

	B±62075E/03		1. GENERAL
	Power unit		200 VAC,
			single phase
	Switching	ON/OFF power	Input unit
	regulator	control
	PMC/CAP board	CPU
	BOOT ROM	PMC engine	I/O unit
	ROM	Memory card I/F	Memory
			card
	RAM	With conversational
	FLASH ROM	function only
		CPU
		ROM
		RAM
	Main CPU board	CPU
	DRAM
	FLASH ROM	CRT control
	SRAM	MDI interface	CRT/MDI
		Serial port	RS232C × 2
		MPG interface	MPG
		High-speed DI	High-speed SKIP
		BUFFER	Multi-axes bus
			to axis shelf
	Sub CPU board
		CPU
	DRAM
	SRAM	Serial port	RS232C × 1, RS422 × 1
		High-speed DI	High-speed SKIP
		A/D, D/A	ANALOG I/O
	Option 1 board	CPU
	ROM	CRT control	To CRT/MDI
	RAM	Graphic control
		CPU
	ROM	Communications	Host computer
	RAM	DMA control
	FAN
	FANUC BUS	NOTE Only the main boards are listed in this diagram

Fig. 1.2 (b) Block Diagram for Series 15±B Multi±axes System (Main Shelf Side)

± 7 ±

1. GENERAL	B±62075E/03

Power unit

Switching

ON/OFF power

regulator

control

Multi-axes buffer board

BUFFER

Axis CPU board (1st)

CPU

DRAM

SERVO control

SRAM

Malfunction check

Spindle control

Axis CPU board (2nd)

CPU

DRAM

SERVO control

SRAM

Malfunction check

Spindle control

Axis CPU board (3rd)

CPU

DRAM

SERVO control

SRAM

Malfunction check

Spindle control

200 VAC, single phase

Input unit

Multi-axes bus

To MAIN shelf side

1st axis to 4th axis

Servo amp.

Pulse coder Servo motor

Reference position proximity signal Position detector

Spindle amp.

		Spindle motor
2nd axis to 8th axis
Servo amp.
Pulse coder
		Servo motor

Reference position proximity signal Position detector

Spindle amp.

	Spindle motor
9th axis to 12th axis
Servo amp.
Pulse coder
	Servo motor

Reference position proximity signal Position detector

Spindle amp.

Spindle motor

Up to six axis CPU boards (24 axes in total) can be installed to expand the system.

FAN

FANUC BUS

Fig. 1.2 (c) Block Diagram for Series 15±B Multi±axes System (Axis shelf side)

± 8 ±

B±62075E/03	1. GENERAL

1.3List of the Printed Circuit Boards and Units of Series 15±B

(a)Control unit rack

Control unit rack

Name		Drawing No.		Remarks
Control unit rack	3 ± SLOT	A02B±0162±C001
	4 ± SLOT	A02B±0162±C002		Standard
	6 ± SLOT	A02B±0162±C003	FANUC
	8 ± SLOT	A02B±0162±C004	name plate
	6 ± SLOT	A02B±0162±C008		Response
	8 ± SLOT	A02B±0162±C009		to MMC±IV	Without
	3 ± SLOT	A02B±0162±C011			Sub.BUS
	4 ± SLOT	A02B±0162±C012		Standard
	6 ± SLOT	A02B±0162±C013	GE±Fanuc
	8 ± SLOT	A02B±0162±C014	name plate
	6 ± SLOT	A02B±0162±C018		Response
	8 ± SLOT	A02B±0162±C019		to MMC±IV
	4 ± SLOT	A02B±0162±C022
				Standard
	6 ± SLOT	A02B±0162±C023
			FANUC name
	8 ± SLOT	A02B±0162±C024
			plate
	6 ± SLOT	A02B±0162±C028		Response
	8 ± SLOT	A02B±0162±C029		to MMC±IV	With
	4 ± SLOT	A02B±0162±C032			Sub.BUS
				Standard
	6 ± SLOT	A02B±0162±C033
			GE±Fanuc
	8 ± SLOT	A02B±0162±C034
			name plate
	6 ± SLOT	A02B±0162±C038		Response
	8 ± SLOT	A02B±0162±C039		to MMC±IV
Power unit
Name		Drawing No.		Remarks
Power unit	AI	A02B±1212±0471
	BI	A02B±1212±0531

± 9 ±

1. GENERAL							B±62075E/03
	Control unit PCB
		Name		Drawing No.	Remarks		Module ID
	Main CPU board	Standard	Main±B	A16B±2201±0320			71
		High±speed	Main±A	A16B±2201±0300			62
			Main C	A16B±3200±0060	Level up		97
		High±speed		A16B±2201±0340	For multiaxis control,		67
		Max Main±A			synchronous control,
					and malfunction
					check
	PMC board	Without conversational		A16B±2201±0371			77
		CPU for PMC ± NA		A16B±2201±0391
		Without conversational		A16B±2201±0381			6B
		CPU for PMC ± NB		A16B±2201±0811
		Without conversational		A16B±2201±0390			77	/ 6D
		CPU for PMC ± NA
		Without conversational		A16B±2201±0810			7B	/ 6D
		CPU for PMC ± NB
	Additional axis board			A16B±2201±0311			63
	Axis CPU board			A16B±2201±0360			7A
	Buffer board			A16B±2201±0351			68
	Sub CPU board	Standard		A16B±2201±0331	Only for multiaxis con-		73
		Max Sub±B			trol, synchronous con-
					trol, and malfunction
					check
		High±speed	Sub±A	A16B±2201±0310			63
			Sub±C	A16B±2202±0571	Level up		A1
	Option 1 board	Graphic+Remote buffer		A16B±2200±0910	Increase	For	45	/ 3F
					of graphic	14ºCRT,
		Graphic+DNC1		A16B±2200±0911			45	/ 3F
					CPU	10ºLCD,
		Graphic		A16B±2200±0912	RAM	or 9º	45
						graphic
		Graphic		A16B±2200±0917	Graphic		45
					CPU RAM
		Graphic+Remote buffer		A16B±2200±0915	(standard)		45	/ 3F
		Graphic+Remote buffer		A16B±2200±0918	Increase	For	45	/ 3F
					of graphic	9.5ºLCD,
		Graphic+DNC1		A16B±2200±0916	CPU	8.4ºLCD,	45	/ 3F
					RAM	or
		Graphic		A16B±2200±0919		MMC±IV	45
		Remote buffer		A16B±2200±0913			3F
		DNC1		A16B±2200±0914			3F
	RISC board			A16B±2201±0710			7F
	ROM cassette adapter			A20B±2000±0760			74
	Back plane PCB
		Name		Drawing No.		Remarks
	Back plane	3±SLOT		A20B±2000±0900	Standard
		4±SLOT		A20B±2000±0710
		6±SLOT		A20B±2000±0720
		8±SLOT		A20B±2000±0730
		6±SLOT		A20B±2001±0650	Response to MMC±IV
		8±SLOT		A20B±2001±0660
		SUB BUS		A20B±1005±0270

± 10 ±

B±62075E/03					1. GENERAL
	Module (For main CPU board)
	Name			Drawing No.	Remarks
	Spindle control		Serial spindle+	A20B±2900±0672
	module		High±speed skip
			Analog spindle+	A20B±2900±0770
			High±speed skip
	Peripheral module			A20B±2900±0660
	FLASH ROM		6MB	A20B±2900±0810
	module
			4MB	A20B±2900±0811
			2MB	A20B±2900±0812
	DRAM module		8MB	A20B±2900±0650
			4MB	A20B±2900±0651
			2MB	A20B±2900±0800
			6MB	A20B±2901±0940	For MAIN±C
			4MB	A20B±2901±0941
			2MB	A20B±2901±0942
	High±speed			A20B±2900±0641
	SRAM module
	SRAM module		2MB	A20B±2900±0682
			1MB	A20B±2900±0680
			512KB	A20B±2900±0681
			256KB	A20B±2900±0700
			128KB	A20B±2900±0701
			64KB	A20B±2900±0711
	Servo control module			A20B±2901±0340	Cannot be used for MAIN±C.
				A20B±2902±0180
	Servo interface module			A20B±2900±0830
				A20B±2901±0360
	CRT control module			A20B±2900±0691	9ºCRT control
	Module (For PMC/conversational board)
	Name			Drawing No.	Remarks
	PMC CPU module		For PMC±NA	A20B±2900±0780
			For PMC±NB	A20B±2901±0581
	PMC engine		For PMC±NA	A20B±2900±0790
	module
			For PMC±NB	A20B±2901±0660
	DRAM module		2MB	A20B±2900±0653
			512KB	A20B±2900±0803
	SRAM module		1.25MB	A20B±2901±0400	For PMC±NB only
			512KB	A20B±2901±0402
	Conversational CPU module			A20B±2901±0390
	EPROM module		1MB	A20B±2900±0290
			768KB	A20B±2900±0291
			512KB	A20B±2900±0292

± 11 ±

1. GENERAL					B±62075E/03
	Module (For PMC/conversational board)
		Name		Drawing No.	Remarks
	DRAM module		1MB	A20B±2900±0550
			512KB	A20B±2900±0551
			128KB	A20B±2900±0555
	SRAM module		512MB	A20B±2900±0541

Module (For Sub CPU board, additional axis board, or axis CPU board)

	Name		Drawing No.	Remarks
Spindle control		Analog spindle+	A20B±2900±0770
module		High±speed skip
		Serial spindle+	A20B±2900±0672	For axis CPU
		High±speed skip
Analog input &			A20B±2900±0721	Serial communication is each one chan-
Serial				nel of RS±422 or RS±232±C.
communication
module
Servo control module			A20B±2901±0340	Cannot be used for SUB±C
			A20B±2902±0180
Servo interface module			A20B±2901±0360
			A20B±2900±0830
DRAM module		2MB	A20B±2900±0800
		1MB	A20B±2900±0802
		2MB	A20B±2901±0942	For SUB±C
High±speed			A20B±2900±0641
SRAM module
SRAM module		512KB	A20B±2900±0681
		256KB	A20B±2900±0700
Module (For RISC board)
	Name		Drawing No.	Remarks
SRAM module		512KB	A20B±2900±0541
ROM module		512KB	A20B±2900±0292
Module (For option 1 board)
	Name		Drawing No.	Remarks
CRT control		14ºCRT	A20B±2901±0370	Standard
module
		10ºLCD 10º PDP	A20B±2901±0372
		9.5º 8.4º LCD	A20B±2902±0272
		9ºCRT 9 ºPDP	A20B±2901±0371
		14ºCRT	A20B±2901±0373	MMC±III
		10ºLCD	A20B±2901±0375
		MMC±IV	A20B±2902±0275	MMC±IV
Communication control module			A20B±2900±0361
Graphic control module			A20B±2900±0310	Standard
			A20B±2900±0311	When MMC±IV or the 9.5º or 8.4º LCD is
				used
Graphic CPU module			A20B±2900±0350

± 12 ±

B±62075E/03						1. GENERAL
	(b) External control unit (except I/O unit)
	Name				Drawing N	Remarks
	9ºCRT/MDI unit	monochrome			A02B±0162±C041
		vertical
		monochrome			A02B±0162±C042
		horizontal
		color vertical			A02B±0162±C051
		color horizontal			A02B±0162±C052
	9ºsmall type	monochrome		M	A02B±0162±C101
	CRT/MDI unit
				T	A02B±0162±C102
	9ºPDP/MDI unit	monochrome			A02B±0162±C061
		vertical
		monochrome			A02B±0162±C062
		horizontal
	9.5ºLCD/MDI unit	color vertical			A02B±0162±C131
		color horizontal			A02B±0162±C132
		color vertical			A02B±0162±C141
		color horizontal			A02B±0162±C142
	10º LCD/MDI unit	color vertical			A02B±0162±C071
		color horizontal			A02B±0162±C072
	10º PDP/MDI unit	monochrome			A02B±0162±C081
		vertical
		monochrome			A02B±0162±C082
		horizontal
	14º CRT/MDI unit	color vertical			A02B±0162±C091
		color horizontal			A02B±0162±C092
		color vertical			A02B±0162±C121	For MMC±IV
		color horizontal			A02B±0162±C122	For MMC±IV
	9ºseparate CRT	monochrome			A02B±0162±C043
	unit
		color			A02B±0162±C053
	9ºseparate PDP	monochrome			A02B±0162±C063
	unit
	Separate MDI unit				A02B±0162±C111
	Connection unit 1				A02B±1005±0310	DI/DO=96/64
	Connection unit 2				A02B±1003±0200	DI/DO=96/64
	Operator's panel	A	DI/DO=64/32		A16B±2200±0661
	connection unit
		B	DI/DO=96/64		A16B±2200±0660
	Optical I/O link adapter				A13B±0154±B001	It is used also for serial spindle interface

± 13 ±

1. GENERAL

B±62075E/03

(c) I/O Unit±MODEL A

Name

Drawing No.

Remarks

Basic unit

ABU10A

A03B±0807±J001

It's possible to mount up to 10 modules.

ABU10B

A03B±0807±J004

Basic unit

ABU05A

A03B±0807±J002

It's possible to mount up to 5 modules.

ABU05B

A03B±0807±J003

Interface

AIF01A

A03B±0807±J011

module

AIF01B

A03B±0807±J012

For slave

AIF02C

A03B±0807±J013

Digital input module

Drawing No.

Type

Point

Voltage

Po-

Resp

Connection

rarity

onse

*1.When

AID32A1

A03B±0807±J101

Non±in

32

DC24V

Both

20ms

Connector A

input is Lo

slation

AID32B1

A03B±0807±J102

32

DC24V

Both

2ms

Connector A

level, it will be

type DC

considered to

AID32H1

A03B±0807±J111

input

32

DC24V

Both

2ms:8

Connector A

turn on.

20ms:8

(0V common)

AID16C

A03B±0807±J103

Inslation

16

DC24V

*1

20ms

Terminal

*2.When

type DC

NEG

block

Input is Hi

input

AID16D

A03B±0807±J104

16

DC24V

*2

20ms

Terminal

level, it will be

DOS

block

considered to

turn on.

AID16K

A03B±0807±J113

16

DC24V

*1

2ms

Terminal

(24V common)

NEG

block

AID16L

A03B±0807±J114

16

DC24V

*2

2ms

Terminal

POS

block

AID32E1

A03B±0807±J105

Inslation

32

DC24V

Both

20ms

Connector A

type DC

input

AID32E2

A03B±0807±J110

32

DC24V

Both

20ms

Connector B

AID32F1

A03B±0807±J106

32

DC24V

Both

2ms

Connector A

AID32F2

A03B±0807±J109

32

DC24V

Both

2ms

Connector B

AID16G

A03B±0807±J107

AC input

16

AC100

ON

30ms

Terminal

±115V

OFF 45ms

block

± 14 ±

B±62075E/03										1. GENERAL
	I/O Unit±MODEL A
	Name			Drawing No.			Remarks
	Digital output module			Drawing No.	Type	point	Voltage	Po-	Resp	Connection
								rarity	once
	*3.When
			AOD32A1	A03B±0807±J162	Non ±	32	DC5	*3	0.3A	Connection A
	turning on,				inslation		±24V	NEG
	output				type DC
	becomes Lo				output
	level.
			AOD08C	A03B±0807±J151	Inslation	8	DC12	*3	2A	Terminal
	(0V common)
					type DC		±24V	NEG		block
	*4.When				output
			AOD08D	A03B±0807±J152		8		*4	2A	Terminal
	turning on							POS		block
	output
	becomes Lo		AOD16C	A03B±0807±J153		16		*3	0.5A	Terminal
	level.							NEG		block
	(24V common)
			AOD16D	A03B±0807±J154		16		*4	0.5A	Terminal
								POS		block
			AOD32C1	A03B±0807±J155		32		*3	0.3A	Connector A
								NEG
			AOD32D1	A03B±0807±J156		32		*4	0.3A	Connector A
								POS
			AOD32D2	A03B±0807±J167		32		*4	0.3A	Connector B
								POS
			AOA05E	A03B±0807±J157	AC output	5	AC100		2A	Terminal
							±230V			block
			AOA08E	A03B±0807±J158		8			1A	Terminal
										block
			AOA12F	A03B±0807±J159		12	AC100		0.5A	Terminal
							±115V			block
			AOR08G	A03B±0807±J160	Relay	8	AC250V		4A	Terminal
					output		/DC30V			block
			AOR16G	A03B±0807±J161		16			2A	Terminal
										block
			AOR16H2	A03B±0807±J165		16	DC30V		2A	Connector B
	Name			Drawing No.			Remarks
	Analog input		AAD04A	A03B±0807±J051	Analog input 4 channels
	module
	Analog output		ADA02A	A03B±0807±J052	Analog output 2 channels
	module
	High±speed		ACT01A	A03B±0807±J052	Pulse input 1 channel
	counter
	module

± 15 ±

2. MAINTENANCE EQUIPMENT	B±62075E/03

2. MAINTENANCE EQUIPMENT

2.1 Maintenance Equipment

The following equipment is recommended. 1) Measuring instruments

Table 2.1 Measuring Instruments for Maintenance

Instrument		Requirements	Usage
AC voltmeter	Capable of measuring AC powersupply		Measurement of AC powersupply volt-
	voltages within a tolerance of ±2%.		age
DC voltmeter	Capable of measuring DC voltages of		Measurement of DC powersupply volt-
	10V and 30V within a tolerance of ±2%		age
	(digital voltmeter may be required).
2) Tools
Phillips screwdriver		: large, medium and small
Standard screwdriver		: large, medium and small

2.2 Main Spare Parts

The following replacement parts should be available:

± Fuses (see 8.1)

± 16 ±

B±62075E/03	3. TROUBLESHOOTING AND ACTION TO BE TAKEN

3. TROUBLESHOOTING AND ACTION TO BE TAKEN

3.1 Procedures for Troubleshooting

The procedures for troubleshooting are classified according to the status of the disabled NC unit as follows. Take the appropriate corrective action as listed below.

(1)	Action to be taken when a system alarm is displayed	See Item 3.2.1.
(2)	Action to be taken when an error code is displayed	See Item 3.2.2.
(3)	An alarm LED lights:	See Item 3.2.3.
(4)	The machine cannot be operated in the jog mode:	See Item 3.2.4.
(5)	The machine cannot be operated by the manual pulse generator:	See Item 3.2.5.
(6)	The spindle cannot be operated in the synchronous feed mode:	See Item 3.2.6.
(7)	The machine cannot be operated in the automatic mode:	See Item 3.2.7.
(8)	The input/output devices of the reader/punch interface do not operate correctly:	See Item 3.2.8.
(9)	The machine does not return to the correct reference position:	See Item 3.2.9.

Items to be checked when a problem occurs

Check the following items and report the results when contacting your FANUC Service Center.

(1)Nature of the problem

i)Mode

ii) Operation or program employed and the tool offset value when the problem occurs

iii)Alarm message

iv)Frequency with which the problem occurs v) The magnitude of a positional error, if any

vi)The position at which the problem occurred

vii)If a system alarm occurs, which LEDs on the PCB are on

(2)Miscellaneous information

i) Series and edition of the software displayed on the screen when the power is turned on

ii)Description of the system parameter (Check the system parameter setting of the machine with the parameter list supplied with to the unit.)

3.2Problems and Corrective Measures

3.2.1 System alarm

If the CNC system encounters a serious failure in the hardware or software and the system decides it impossible to continue operation, it stops normal operation and enters the system alarm state. In this state, the system automatically analyzes possible causes of the failure and displays the result on the screen. In most cases, it is not possible for users to restore the system. Check the items described in 3.1 and contact your FANUC Service Center.

All information displayed on the screen is stored in the memory in the CNC system. Therefore, it is possible to refer to the information on the system history screen after the system is restored and the power is turned on again.

For details on the system alarms and how to display the system history screen, refer to Appendixes 1 and 2.

± 17 ±

3. TROUBLESHOOTING AND ACTION TO BE TAKEN	B±62075E/03

3.2.2 Action to be taken when an error code is displayed

If the CNC system detects an error, it displays the corresponding error code and alarm message on the screen.

The error codes and alarm messages are listed in the Operator's Manual (Programming). For an explanation of servo alarms, refer to the relevant maintenance manual. Each servo alarm is described, together with the corresponding corrective action.

The following covers important alarms and the actions to be taken.

(1)PS200 PULSE CODER SYNCHRONOUS ERROR

While returning to the reference position, either a one±rotation signal is not sent from the pulse coder or the signal is sent but the motion is too slow.

When a pulse coder is employed, the reference counter is synchronized with the one±rotation signal the first time the machine returns to the reference position after the power is turned on or an emergency stop is reset. In this synchronization, the following conditions must be met so that the same edge of the one± rotation signal can be detected.

(A)The positional deviation (diagnosis function No. 3000) must be at least 128.

(B)One or more one±rotation signals must be sent after the positional deviation (diagnosis function No. 3000) has been at least 128 (but before the deceleration dog is released again).

The one±rotation signal is not used when the machine returns to the reference position the second or subsequent time. Thus, this alarm does not occur after the machine has returned to reference position the first time.

	Item	Possible cause of the	How to check the cause	Action to take
		problem
			Return the machine to the reference posi-
			tion under the same system conditions
			system as when the alarm occurred.	Increase the feedrate.
			Then, check the positional deviation
			(diagnostic data, parameter No.3000) us-	When the position gain is
	1	The feedrate is too slow.	ing the self±diagnosis function and check	30sec±1, the feedrate
			that the deviation exceeds 128. In particu-	should be 300 mm/min or
			lar, carefully check the deviation when the	more.
			machine returns to the reference position
			from the position at which the deceleration
			dog is pressed.
		The position at which the		Use a start position whose
		machine starts returning to	Check the distance between the start	distance from the refer-
	2	the reference position is		ence position is equivalent
		too close to the reference	position and the reference position.	to two or more motor rota-
		position.		tions.
			Check that the voltage through the pulse
			coder is 4.75V or above.
			To check the voltage through the	The voltage drop through
		The power supply voltage	pulse coder, remove the cover of
			the servo motor and measure the	the cables must be 0.2V
	3	to the pulse coder is too
			voltage between the positive and	or less in total in both the
		low.
			negative terminals on the printed	5±V line and 0±V line.
			circuit board of the pulse coder or
			between the land connected to
			the +5 V and the 0 V lines.
	4	The pulse coder is defec-	Replace the pulse coder and check that	Replace the pulse coder.
		tive	the error is eliminated.
		The main CPU board or	Replace the printed circuit board to which
	5		the erroneous axis is connected, and	Replace the pulse coder.
		sub board is defective.	check that the error is eliminated.

± 18 ±

B±62075E/03	3. TROUBLESHOOTING AND ACTION TO BE TAKEN

(2)OT 007 + OVERTRAVEL (HARD) OT 008 ± OVERTRAVEL (HARD)

The above alarm message is displayed on the screen if the machine reaches the end of the stroke. When this alarm occurs in the automatic mode, the machine stops motion along all axes. In the manual mode, only motion along the axis on which the alarm occurred stops.

Each axis of the machine is equipped with two limit switches (LS1 and LS2) as shown below along each direction, and they stop the movable parts of the machine

Feedrate

Position

LS1

LS2

When LS1 is actuated …… The machine decelerates and stops.

Then, the above message is displayed on the screen. When LS2 is actuated …… The machine stops immediatery, as in an emergency stop.

(LS2 operates only if LS1 is defective.)

(Causes and counter measures)

1. The wrong reference position was specified in setting the coordinate system.

	→ Modify the program.
2. The program has bugs in it.	→ Modify the program.
(How to reset the error)
(a) When only LS1 is actuated:

Move the machine manually in the opposite direction in the jog, step, or handle mode and disengage it from the limit switch. Then, press the RESET button on the MDI panel.

NOTE It is only possible to move the machine toward the normal operating area.

(b)When both LS1 and LS2 are actuated:

1.Press on the 2ND LS release button.

2.Follow the same step as above for resetting LS1.

NOTE For a machine on which LS1 does not operate when LS2 is actuated, the machine can be moved manually in both directions. Take care not to move the machine in the wrong direction.

(3) OT 001 + OVERTRAVEL (SOFT1)

Stored stroke limit alarms

OT 006 ± OVERTRAVEL (SOFT3)

The above alarm message is displayed on the screen when the machine reaches the stored stroke limit. When this alarm occurs in the automatic mode, the machine stops moving along all axes. In the manual mode, only motion along the axis on which the alarm occurred stops.

(Causes)

(a)The program has bugs in it.

(b)The wrong stroke limit was stored.

(Check)

The position of the machine in the machine coordinate system relative to the reference position can be checked on the position display screen.

(Counter measures)

(a)Modify the program.

(b)Store a correct stroke limit.

± 19 ±

3. TROUBLESHOOTING AND ACTION TO BE TAKEN	B±62075E/03

(How to reset the error)

(a)The machine can be moved only toward the normal operating ranges.

(b)When the machine has stopped in the restricted zone and cannot escape it, press the emergency stop button to reset the alarm. Then, specify G23 on the MDI panel to disable the stored stroke limit function and move the machine in the jog mode.

(4)SV 013 IMPROPER V±READY OFF

	Item	Possible cause of the	How to check the cause	Action to take
		problem
				Proceed to item 2 when
	1	Fault analysis	Check if green LED DRDY lights in ser-	LED DRDY lights. Pro-
			vo amplifier PCB.	ceed to item 8 when it
				does not light.
				If this LED lights, locate
				and eliminate the cause of
	2	Fault analysis	Check if alarm LED lights in servo ampli-	the alarm ( see the fllow-
			fier PCB.	ing 1st, A±D).prossees to
				item 3, when this LED
				does not light.
				Proceed to item 8 when
	3	Fault analysis	Check if electromagnetic contractor	MCC is energized. Pro-
			MCC is turned on in servo amplifier.	ceed to item 4 when it is
				not energized.
			Check if 100V is applied between termi-	Proceed to item 9 when
	4	Fault analysis	nals (3) and (4) of terminal board T1 of	power is applied. Proceed
			servo amplifier.	to item 5 if not applied.
			Check 100V power supply Check if
	5	Signals from machine tool	emergency stop signal is sent from ma-	Restore to normal condi-
			chine tool or if the machine tool is ready	tions.
			for operation.
	6	Trouble in servo amplifier	Servo amplifier PCB or MCC is defec-	Replace.
			tive.
			Poor contact between servo amplifier
	7	Poor contact	and main CPU or option 2 board, or a	Replace.
			problem in master PCB.
	8	Poor contact	Poor contact inside servo amplifier or a	Replace.
			trouble in servo amplifier PCB.
	9	No fuse breaker in turned	Check the no fuse breaker button on/off	If it is not off, proceed to
		off.	state	item 6.
			The operating conditions as illustrated
			below.
			While the motor operates nor-	Reset the no fuse breaker
			mally, this lever is at upper
			position and the ON indication	after turning off the power
			can be seen. If the circuit	supply.
	10	No fuse breaker functions	breaker trips, the lever moves	( if the no fuse breaker
			to the lower position and the	trips immediately then wait
			OFF indication appears. To	for about 10 minutes be-
			reset the breaker turn off the	fore attempting another
			three±phase power supply,	breaker reset.)
			and move the lever to the up-
			per position.
		Diode module, surge ab-	No fuse breaker functions when power	Replace diode module DS
		sorber (TNR) or other
	11		supply is turned on after the corrective	or surge absorber (ZNR)
		parts are faulty in servo
			action in item 1.	of servo amplifier.
		amplifier.

± 20 ±

B±62075E/03	3. TROUBLESHOOTING AND ACTION TO BE TAKEN

(5)SV 008 EXCESS ERROR (STOP) SV 009 EXCESS ERROR (MOVING) Excessive positional deviation alarm

	Item	Possible cause of the	How to check the cause	Action to take
		problem
		An incorrect positional	Check that the settings in parameter	Set the parameters to the
	1		Nos. 1828 to 1830 conform to the pa-
		deviation is specified.		correct settings.
			rameter list supplied with the NC unit.
			When the current necessary to acceler-
			ate or decelerate the motor in accor-	Increase the rapid tra-
			dance with the the acceleration/decel-
	2	Overshoot		verse time constant of the
			eration of the NC unit does not pass
				NC unit. (Specify it on the
			through the motor, the amount of error in
				control unit.)
			the positioning control circuit increases
			for some time.
		The input power supply	Measure the input power supply voltage	Set the proper voltage on
	3		and check that it is within the range of	the input tap of the power
		voltage is too low.
			+10% to ±15%.	transformer for the servo.
	4	Incorrect cable connection	Check that cables such as the motor	Connect the cables cor-
			power line are connected correctly.	rectly.
		The main CPU board or	If a spare board is available, replace de-
		sub board is defective, or	fective board and check that the alarm	Replace the printed circuit
	5	the printed circuit board of	does not occur. When using a new
				board.
		the servo amplifier is de-	board, ensure that it is correctly adjusted
		fective.	and set.

± 21 ±

3. TROUBLESHOOTING AND ACTION TO BE TAKEN	B±62075E/03

3.2.3 Lighting of alarm LEDs on PCBs

If an alarm condition occurs, an alarm message is usually displayed on the CRT screen. The state of the PCB when the alarm occurred is indicated by the LEDs on the front panel of each control unit PCBs, as shown below.

When a system alarm occurs, the alarm message displayed on the screen, together with the LED indications on each PCB, help you to determine the cause. Record the LED indications for each PCB to enable rapid recovery of the system.

For the descriptions of LED lamps on each printed circuit board, see Chapter 7.

1	2	3	4
STATUS			LED (G ee ) i dica i g
ALARM			a e f he ce
			i ed ci c i b a d

LED (Red) i dica i g a a

f he i ed ci c i b a d

Fig. 3.2.3 LED Display for the Printed Circuit Boards in the Control Unit

± 22 ±

B±62075E/03	3. TROUBLESHOOTING AND ACTION TO BE TAKEN

3.2.4 The machine cannot be operated in the jog mode.

Item	Possible cause of the		How to check the cause	Action to take
	problem
		Check whether the position display
		changes with the display lock (DLK)
		turned off.
		1.	The position display
1	Failure analysis		changes but the machine	See Item 2.
			cannot be moved.
		2.	Neither the position
			display changes nor can	See Item 5.
			the machine be moved.
2	The machine lock (MLK)	Check the MLK signal in the DGN data.
	is on.
3	The servo off signal is on.	Check the servo off signal in the DGN
		data. Check parameter No. 1802.
4	Malfunction in the servo	Refer to the ªFANUC AC Servo Unit
	system	Maintenance Manual.º
5	The interlock signal is on.	Check DGN data (parameter No. 1000).
	The JOG override is 0%.
6	The mode signal is not	Check that JOG or J + H is displayed for
	input.	the status.
		Check the DGN data to see if the feed
		axis direction signal is input.
		Note When an axis command is input
7	The feed axis direction		before the jog mode is selected,
			movement along the specified
	signal is not input.
			axis will not start.
			To start the movement, cancel the
			axis command and then input it
			again.
		Check parameter No. 1423.
	An improper jog feedrate	If the machine cannot be operated at
8		rapid traverse, check the rapid traverse
	is specified.
		feedrate in parameters No. 1420 and
		thereafter.
9	External reset (ERS) is on.	Check that RSET is displayed for the		Check the connection.
	Reset and rewind (RRW)	status.
	is on.
10	Reference position return	Check that REF is displayed for the sta-		Check the connection.
	(ZRN) is on.	tus.

± 23 ±

3. TROUBLESHOOTING AND ACTION TO BE TAKEN	B±62075E/03

3.2.5 The machine cannot be operated by the manual pulse generator.

	Item	Possible cause of the	How to check the cause	Action to take
		problem
			Check whether the position display
			changes when the display lock (DLK) is
			off.
	1	Failure analysis	1. The position display changes but	See Item 2.
			the machine cannot be moved.
			2. Neither the position display changes	See Item 5.
			nor can the machine be moved.
	2	The machine lock (MLK)	Check the DGN data.
		is on.
	3	The servo off signal is on.	Check the DGN data.
			Check parameter No. 1802.
	4	Malfunction in the servo	Refer to the ªFANUC AC Servo Unit
		system	Maintenance Manual.º
	5	The interlock signal is on.	Check the DGN data.
		The JOG override is 0%.	(parameter No. 1000).
	6	The mode signal is not in-	Check that HND or J + H is displayed for
		put.	the status.
	7	The feed axis selection	Check the DGN data to see if the feed
		signal is not input.	axis selection signal is input.
	8	External reset (ERS) is on.	Check that RSET is displayed for the
		Reset and rewind (RRW)	status.
		is on.
	9	Reference position return	Check that REF is displayed for the sta-
		(ZRN) is on.	tus.
		The manual pulse genera-
	10	tor is defective.
		The cables are defective.
	11	Correct options are not	Check the options with the data sheet.
		added.

3.2.6 The spindle cannot be operated in the synchronous feed mode.

	Item	Possible cause of the	How to check the cause	Action to take
		problem
	1	Incorrect cable connection	Check the connection between the NC
			unit and the position coder.
		The spindle speed is in-	Check the spindle speed on the screen.
	2		Check the DGN data.
		correct.
			(parameter No. 1000).
	3	The position coder is de-		Replace the position cod-
		fective.		er.
	4	The main CPU board is		Replace the main CPU
		defective.		board.

± 24 ±